5000 Hours—5 Yearly Off Line Mechanical Inspection

BUCYRUS Australia Room and Pillar

Preventative Maintenance Inspection

Job Description: 5000 Hour – 5 Yearly Off Line Mechanical Inspection

BUCYRUS FBL-10 LHD/Utility Vehicle

Job No:

Customer: Type: FBL-10

Mine:

Technical References

BUCYRUS : FBL-10 Service Manual AS3584-3 : Diesel Engine Systems for Underground Coal Mines-Maintenance

Safety Advice

 Determine which energy source will need isolating before starting work.  Isolate and tag all forms of energy that could put you at risk.  Work safely and ensure your actions do not put others at risk.

General Notes

 Use only the correct tools for the job.  Examine any lifting device is fit for purpose before use.  While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.  Check infers “look, listen, feel”

References

 Personal Protection Equipment Policies  Occupational Health and Safety Regulations  Mine Manager’s Rules  Isolation and Tagging procedures  SOPs where relevant

Condition Codes

1. No fault found 2. Fault found and fixed, record fault and parts used. 3. Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

 Perform activity.  Indicate condition by placing a tick against the appropriate code.  Document any comments including any defects found.  Print name or initial to indicate the activity is complete.  Print name and sign and date in the “Completed By” table at the end of the service sheet.

SERIAL No.: PLANT No.: DATE:

Tick Box

Activity Required 1 2 3 Defects/Comment

Record Hour Meter Reading _________ hrs

Clean machine completely, pay particular attention to loose material, oil and coal dust.

1. ENGINE - General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive). Drain and refill engine oil

Replace Engine oil filter Inspect the engine for the correct oil level. Top up as required. Indicate litres used.

Check engine breather If fitted with Hydraulic throttle, inspect throttle fluid reservoir and fill as required. Indicate litres used

If fitted with cable throttle, inspect condition of cable. Ref: Spec 1

BUCYRUS Part No. 503469

Ref: Spec 1

Ref: Spec 3

1.2 ENGINE - Intake

Check the air filter restriction indicator for signs of filter contamination/blockage. Check condition of filter housing. Check the Primary air filter element and replace if required. Check Inner air filter element and replace if required. Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness Check all other intake joints for security and tightness Check all air intake hoses, pipes and fittings for damage, leaks and looseness. BUCYRUS Part No. 505090

BUCYRUS Part No. 505089

Tick Box

Activity Required 1 2 3 Defects/Comment

1.3 ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required. Inspect condition and security of seal in cap for diesel tank manual fill point.

Replace Primary fuel filter

Replace Secondary fuel filter

Check fuel water separator and drain off any water as required. Check fuel level in fuel tank and fill as required. Indicate litres used BUCYRUS Part No. 503467

BUCYRUS Part No. 506604

Ref: Spec 6

1.4 ENGINE - Cooling System

Inspect the cooling system header/ expansion tank for the correct coolant level. Top up as required. Indicate litres used. Check condition of header tank pressure caps and necks. Inspect the cooling pump for signs of leakage, wear and security. Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security. Pressure clean radiator assemblies, check mounts and re-torque as required. Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/ replace as required. Check fan blades and cowl for correct operation and alignment. Ref: Spec 5

BUCYRUS Part No. 504611

Tick Box

Activity Required 1 2 3 Defects/Comment

1.5 ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage. Check particulate filter.

1.6 ENGINE - Exhaust Cooling System

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve. Clean exhaust chamber. Drain, remove covers. Flush out, remove exhaust build up.

2. DRIVETRAIN - Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive). Check Transmission Strainer

Check transmission breather

Drain and refill Transmission oil

Replace Transmission filter element Check transmission oil level and top up as required. Indicate litres used.

2.1 DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required. Ref: Spec 2

2 x BUCYRUS Part No. 501471

Ref: Spec 2

Tick Box

Activity Required 1 2 3 Defects/Comment

2.2 DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing. Tighten / replace as required. Inspect the tyre assemblies for damage (tears/splits) and wear. Record the amount of wear, ____%. Replace as required. Check tyre pressure.

ODSF ____% ODSR ____% DSF ____% DSR ____%

2.3 DRIVETRAIN - Axles and Planetaries

Check for any oil leaks. Drain, flush and refill front and rear Axle and wheel end oils

Check Axle levels and fill as required. Indicate litres used.

Front Rear

Check pinion oil seals Check differential breathers

Front Rear

2.4 DRIVETRAIN - Brakes

Check wear measurements on all brake units

ODSF ODSR DSF DSR Ref: Spec 4

Ref: Spec 4

Tick Box

Activity Required 1 2 3 Defects/Comment

3. HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used. Ensure the hydraulic filler cap is secure and sealing. Remove, re-seal and test the Service brake valve

Check and record the following gauge pressures:

Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Ref: Spec 3

Note: Machine Not To Be Operated if Brake Head pressure is below 1750 PSI

Replace Steering circuit pressure filter

Replace Hydraulic Return filter

Replace Alternator Pressure Filter BUCYRUS Part No. 501800

BUCYRUS Part No. 502126

BUCYRUS Part No. 641114

4. PNEUMATICS - Air Receiver

Drain away all condensation from the air receiver vessel.

Drain air circuit water trap. Check governor setting. Inspect the circuit and relief valve for damage, leaks and correct operation. Replace Air compressor filter. BUCYRUS Part No. 503715

4.1 PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

4.2 PNEUMATICS - Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labelled. Repair as required.

4.3 PNEUMATICS - Brake valves

Replace the Park/Emergency Brake valve

Replace the Park Brake Air Pilot valve BUCYRUS Part No. 500438

BUCYRUS Part No. 502103

Tick Box

Activity Required 1 2 3 Defects/Comment

5. ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment

Ensure compartment is clean of all loose materials, coal, dirt etc. Inspect the condition of the operators gauges. Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operators seat for physical damage, including cushions and pads. Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required. Inspect tilt/lift and implement control valve boots for damage and replace if necessary. Check door hinges and latches for correct operation. Repair as required. Inspect and clean under dash.

Drain Safety System air circuit water trap.

5.1 ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System

Check Lights for correct operation. Check cables, hoses and flameproof joints are secure.

Check DCS installation for security. Check alignment, condition and mounting of alternator, drive coupling and motor.

6. FRAME RELATED - Canopy

Check for damage, security of fasteners

6.1 FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

Tick Box

Activity Required 1 2 3 Defects/Comment

6.2 FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/ holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in. Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

6.3 FRAME RELATED - Fire Suppression System – If Fitted

Inspect the security of all fittings and components of the fire suppression systems. Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

6.4 FRAME RELATED - Lubrication

Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x RAS Cradle – Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 4 x

Lubricate the engine drive coupling

6.5 FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required. Ref: Spec 7

Ref: Spec 8

Tick Box

Activity Required 1 2 3 Defects/Comment

7. OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation. Select a gear and check if the engine will attempt to start. Repair as required. Check the door interlock system for correct operation, moving in 1st gear slow. Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Perform wet bath low water shutdown test.

Note: Machine Not To Be Put In Operation If Safety Systems Are Not Working

7.1 OPERATIONAL CHECKS - Hydraulic

Function Test all Hydraulic Operations Steering; left and right Bucket Tilt; forward and back Bucket Lift; raise and lower Bucket eject; in and out (If fitted) RAS; lock and unlock Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x RAS cylinder 1 x

7.2 OPERATIONAL CHECKS—Tyres

Check tyres for cuts, punctures, tread depth and correct pressure.

Comment:

Inspected By:

Checked By: Date:

Date:

FBL-10 LHD/UTILITY VEHICLE – LUBRICATION REFERENCE

COMPONENT CAPACITY (Litres) LUBRICANT

1 Engine 26 Engine Oil

TEMPERATURE

BELOW 0ºC 0-32ºC ABOVE 32ºC

SAE15W-40 API CD-II (Valvoline - Super Diesel 15W -40 or Equivalent) SAE40 API CD-II (Valvoline - All Fleet Premium 40 or Equivalent) SAE50 API CD-II (Valvoline - All Fleet Premium 40 or Equivalent)

2 Transmission 40 Mineral Gear Oil SAE10W CAT TO-4 (Valvoline -Valtorque C4 10W or Equivalent) SAE30 CAT TO-4 (Valvoline -Valtorque C4 30 or Equivalent) SAE50 CAT TO-4 (Valvoline Valtorque C4 50 or Equivalent)

3 Hydraulic 300 Hydraulic

4 Axle / Wheel Ends

35 (Each Axle)

5 Cooling System 72 Mineral Gear Oil with Limited Slip Additive

Pre-mixed Coolant Conditioner ISO68 (Valvoline - Ultramax HVI 46 or Equivalent) ISO68 (Valvoline - Ultramax 68 or Equivalent) ISO68 (Valvoline - Ultramax 68 or Equivalent)

SAE90LS (Valvoline - HP Gear Oil LS SAE90 or Equivalent)

Ethylene Glycol Antifreeze Inhibitor to GM 6038-M (Valvoline - Heavy Duty Coolant 50 or Equivalent)

6 Fuel 300 Distillate “Diesel” Fuel To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

7 Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin

8

Wet Exhaust Conditioner Make Up Water Tanks

9 Engine Drive Coupling As required Multi-purpose

EP Grease

780 Water

Refer Service Manual

High Temperature NLGI No. 0 or 1 (Shell - Alvania EP 0/1 or equivalent) NLGI No. 2 (Valvoline - Valplex EP 2 or equivalent) NLGI No. 2 (Valvoline - Valplex EP 2 or equivalent)

NLGI no. 2 (Shell Stamina RL2)